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NASA NTRS1989

Aging behavior and life prediction of graphite composites

This paper presents experimental data from two independent tests, designed to determine the long-term reliability of composite materials. The technique of accelerated aging at elevated temperatures is employed. In the first set, graphite fiber, epoxy composites in five ply layups are manufactured and tested in the standard short-beam shear mode. In the second set, Nomex honeycomb, graphite fiber/epoxy composite face and rear sheet sandwich coupons are tested. After satisfying simple consistency checks, data interpretation is attempted within the framework of an Arrhenius degradation model. The elevated temperature is assumed to influence the degradation according to this temperature-dependent rate law. From these tests on five-ply composites and honeycomb sandwiches, it is concluded that aging is not a serious problem.

Ramohalli, Kumar↗

DOE OSTI2023

Final Technical Report: Innovative Magnetron Power Sources for Superconducting RF (SRF) Accelerators

In this project, MUONS is designing and building custom magnetrons at Richardson Electronics (RELL) to test the predictions of the models and make improvements to the designs to match the needs of NP SRF accelerators and their life-cycle costs. To increase lifetime, the filament temperature is controlled by a feedback circuit that includes a model of back streaming of electrons. The gain of the magnetron is optimized by the design of an input port. A permanent magnet design with trim coil for amplitude adjustment reduces energy consumption. Moving the construction of the magnetron from prototype to manufacturing includes the utilization of RELL processes and designs. To the extent that outgassing of materials influences the lifetime of the magnetron, methods for minimizing outgassing was explored. Further experimentation of the potential of sub-critical voltage operation continues to be explored. The commercialization goal of the project will be naturally achieved as RELL already has world-wide marketing, sales, and support to exploit the assembly-line capabilities generated by this project to enable magnetron technologies for NP accelerators.

43 PARTICLE ACCELERATORS↗

NASA NTRS1976

Performance documentation of the Engineering Model 30 cm diameter Thruster

Presented are the results of extensive testing of two 30-cm ion thrusters which are virtually identical to the 900 series Engineering Model Thruster in an ongoing 15,000-hour life test. Included are performance data for the nominal full-power (2650 W) operating point; performance sensitivities to discharge voltage, discharge losses, accelerator voltage, and magnetic baffle current; and several power throttling techniques (maximum Isp, maximum thrust/power ratio, and two cases in between). Criteria for throttling are specified in terms of the screen power supply envelope, thruster operating limits, and control stability. In addition, reduced requirements for successful high voltage recycles are presented.

Bechtel, R. T.↗

NASA NTRS1985

Design Evaluation of High Reliability Lithium Batteries

Within one year, a lithium battery design can be qualified for device use through the application of accelerated discharge testing, calorimetry measurements, real time tests and other supplemental testing. Materials and corrosion testing verify that the battery components remain functional during expected battery life. By combining these various methods, a high reliability lithium battery can be manufactured for applications which require zero defect battery performance.

Buchman, R. C.↗

DOE OSTI2014

International PV QA Task Force's Proposed Comparative Rating System for PV Modules: Preprint

The International PV Quality Assurance Task Force is developing a rating system that provides comparative information about the relative durability of PV modules. Development of accelerated stress tests that can provide such comparative information is seen as a major step toward being able to predict PV module service life. This paper will provide details of the ongoing effort to determine the format of such an overall module rating system. The latest proposal is based on using three distinct climate zones as defined in IEC 60721-2-1 for two different mounting systems. Specific stresses beyond those used in the qualification tests are being developed for each of the selected climate zones.

14 SOLAR ENERGY↗

DOE OSTI2016

MO-FG-202-04: Gantry-Resolved Linac QA for VMAT: A Comprehensive and Efficient System Using An Electronic Portal Imaging Device

Purpose: To automate gantry-resolved linear accelerator (linac) quality assurance (QA) for volumetric modulated arc therapy (VMAT) using an electronic portal imaging device (EPID). Methods: A QA system for VMAT was developed that uses an EPID, frame-grabber assembly and in-house developed image processing software. The system relies solely on the analysis of EPID image frames acquired without the presence of a phantom. Images were acquired at 8.41 frames per second using a frame grabber and ancillary acquisition computer. Each image frame was tagged with a gantry angle from the linac’s on-board gantry angle encoder. Arc-dynamic QA plans were designed to assess the performance of each individual linac component during VMAT. By analysing each image frame acquired during the QA deliveries the following eight machine performance characteristics were measured as a function of gantry angle: MLC positional accuracy, MLC speed constancy, MLC acceleration constancy, MLC-gantry synchronisation, beam profile constancy, dose rate constancy, gantry speed constancy, dose-gantry angle synchronisation and mechanical sag. All tests were performed on a Varian iX linear accelerator equipped with a 120 leaf Millennium MLC and an aS1000 EPID (Varian Medical Systems, Palo Alto, CA, USA). Results: Machine performance parameters were measured as a function of gantry angle using EPID imaging and compared to machine log files and the treatment plan. Data acquisition is currently underway at 3 centres, incorporating 7 treatment units, at 2 weekly measurement intervals. Conclusion: The proposed system can be applied for streamlined linac QA and commissioning for VMAT. The set of test plans developed can be used to assess the performance of each individual components of the treatment machine during VMAT deliveries as a function of gantry angle. The methodology does not require the setup of any additional phantom or measurement equipment and the analysis is fully automated to allow for regular routine testing.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2022

Use of a silver-based sanitizer to accelerate Escherichia coli die-off on fresh-cut lettuce and maintain produce quality during cold storage: Laboratory and pilot-plant scale tests

Outbreaks and product recalls involving romaine and iceberg lettuce are frequently reported in the United States. Novel technologies are needed to inactivate pathogens without compromising product quality and shelf life. In this study, the effects of a process aid composed of silver dihydrogen citrate, glycerin, and lactic acid (SGL) on Escherichia coli and Listeria monocytogenes concentrations on lettuce immediately after washing and during cold storage were evaluated. Sensory and quality attributes of fresh-cut iceberg lettuce were also evaluated. Laboratory results indicated that application of SGL solution for 30 s as a first step in the washing process resulted in a 3.15 log reduction in E. coli O157:H7 immediately after washing. For E. coli O157:H7 a significant difference between SGL treatment and all other treatments was maintained until day 7. On day zero, SGL led to a 2.94 log reduction of L. monocytogenes. However, there was no significant difference between treatments with or without SGL regardless of storage time. Pilot-plant results showed that samples receiving SGL spray followed by chlorinated flume wash exhibited a greater reduction (1.48 log) in nonpathogenic E. coli populations at the end of shelf life than other treatments (p < 0.05). Additional pilot plant tests were conducted to investigate the hypothesis that SGL residues could continue to impact microbial survival on the final washed lettuce. Results show that pathogens introduced subsequent to flume washing of lettuce pretreated with SGL solution were not affected by antimicrobial residues. Here, the final quality and shelf life of flume washed lettuce were also unaffected by pretreatment with SGL. In conclusion, the results of this study demonstrate that this new technology has the potential to accelerate E. coli die-off on fresh-cut lettuce during cold storage and improve product safety, while not affecting quality throughout the shelf life of the finished products.

59 BASIC BIOLOGICAL SCIENCES↗

NASA NTRS1990

Long-term photothermal/humidity testing of photovoltaic module polymer insulations and cover films

The life expectancies of Tedlar and other polymer films considered for use as cover materials in terrestrial photovoltaic (PV) modules were investigated by exposing them for more than 13,000 h on an outdoor test stand and for up to 10,000 h in several accelerated multistress environments. Visual observations and diagnostic analyses of weight and mechanical strength losses were periodically conducted to assess the nature and rate of degradation of mechanical properties and to assess the effects of film thickness and UV stabilizer content. Spectroscopic analyses of pristine and degraded materials linked weight and mechanical property losses to the underlying photothermal/photooxidation chemistry. It is shown that heavy doses of UV stabilizers prolong, while elevated temperatures shorten, the useful life of these materials; humidity plays only a minor role. The most heavily UV-stabilized films are expected to operate usefully in a PV module front-cover application for only five to ten years. The performance of none of the tested films appears consistent with the 20-30 year life goals of the PV industry.

Mon, G.↗

NASA NTRS2012

Accelerated Creep Testing of High Strength Aramid Webbing

A series of preliminary accelerated creep tests were performed on four variants of 12K and 24K lbf rated Vectran webbing to help develop an accelerated creep test methodology and analysis capability for high strength aramid webbings. The variants included pristine, aged, folded and stitched samples. This class of webbings is used in the restraint layer of habitable, inflatable space structures, for which the lifetime properties are currently not well characterized. The Stepped Isothermal Method was used to accelerate the creep life of the webbings and a novel stereo photogrammetry system was used to measure the full-field strains. A custom MATLAB code is described, and used to reduce the strain data to produce master creep curves for the test samples. Initial results show good correlation between replicates; however, it is clear that a larger number of samples are needed to build confidence in the consistency of the results. It is noted that local fiber breaks affect the creep response in a similar manner to increasing the load, thus raising the creep rate and reducing the time to creep failure. The stitched webbings produced the highest variance between replicates, due to the combination of higher local stresses and thread-on-fiber damage. Large variability in the strength of the webbings is also shown to have an impact on the range of predicted creep life.

Jones, Thomas C.↗

DOE OSTI2024

Design of a first-of-A-kind instrumented advanced test reactor irradiation Capsule experiment for In situ thermal conductivity measurements of metallic fuel

Metallic fuel undergoes dramatic microstructural changes early in life due to fission gas swelling until ~2–3 at% burnup which affects the conductivity of the material, however the evolution of metallic fuel thermal conductivity during this early phase burnup has never been successfully measured in situ. The Irradiated Material Properties Accelerated Characterization Test (IMPACT) experiment will be the first in a series of experiments to irradiate advanced nuclear metallic fuel specimens with novel embedded thermal conductivity probes in ATR. In the current work the IMPACT experiment final design and supporting analysis is reported in detail. Results are evaluated for various reactor operational conditions to meet the functional requirements of the experiment. Finally, the first iteration of this IMPACT experiment will provide data regarding thermal properties evolution in uranium-zirconium (U10Zr) fuel, but this experiment vehicle is envisioned for future advanced fuels and structural materials irradiations in ATR.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

SU-F-T-313: Clinical Results of a New Customer Acceptance Test for Elekta VMAT

Purpose: To report the results of a customer acceptance test (CAT) for VMAT treatments for two matched Elekta linear accelerators. Methods: The CAT tests were performed on two clinically matched Elekta linear accelerators equipped with a 160-leaf MLC. Functional tests included performance checks of the control system during dynamic movements of the diaphragms, MLC, and gantry. Dosimetric tests included MLC picket fence tests at static and variable dose rates and a diaphragm alignment test, all performed using the on-board EPID. Additionally, beam symmetry during arc delivery was measured at the four cardinal angles for high and low dose rate modes using a 2D detector array. Results of the dosimetric tests were analyzed using the VMAT CAT analysis tool. Results: Linear accelerator 1 (LN1) met all stated CAT tolerances. Linear accelerator 2 (LN2) passed the geometric, beam symmetry, and MLC position error tests but failed the relative dose average test for the diaphragm abutment and all three picket fence fields. Though peak doses in the abutment regions were consistent, the average dose was below the stated tolerance corresponding to a leaf junction that was too narrow. Despite this, no significant differences in patient specific VMAT quality assurance measured were observed between the accelerators and both passed monthly MLC quality assurance performed with the Hancock test. Conclusion: Results from the CAT showed LN2 with relative dose averages in the abutment regions of the diaphragm and MLC tests outside the tolerances resulting from differences in leaf gap distances. Tolerances of the dose average tests from the CAT may be small enough to detect MLC errors which do not significantly affect patient QA or the routine MLC tests.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2016

Poster - 44: Development and implementation of a comprehensive end-to-end testing methodology for linac-based frameless SRS QA using a modified commercial stereotactic anthropomorphic phantom

Purpose: An end-to-end testing methodology was designed to evaluate the overall SRS treatment fidelity, incorporating all steps in the linac-based frameless radiosurgery treatment delivery process. The study details our commissioning experience of the Steev (CIRS, Norfolk, VA) stereotactic anthropomorphic head phantom including modification, test design, and baseline measurements. Methods: Repeated MR and CT scans were performed with interchanging inserts. MR-CT fusion accuracy was evaluated and the insert spatial coincidence was verified on CT. Five non-coplanar arcs delivered a prescription dose to a 15 mm spherical CTV with 2 mm PTV margin. Following setup, CBCT-based shifts were applied as per protocol. Sequential measurements were performed by interchanging inserts without disturbing the setup. Spatial and dosimetric accuracy was assessed by a combination of CBCT hidden target, radiochromic film, and ion chamber measurements. To facilitate film registration, the film insert was modified in-house by etching marks. Results: MR fusion error and insert spatial coincidences were within 0.3 mm. Both CBCT and film measurements showed spatial displacements of 1.0 mm in similar directions. Both coronal and sagittal films reported 2.3 % higher target dose relative to the treatment plan. The corrected ion chamber measurement was similarly greater by 1.0 %. The 3 %/2 mm gamma pass rate was 99% for both films Conclusions: A comprehensive end-to-end testing methodology was implemented for our SRS QA program. The Steev phantom enabled realistic evaluation of the entire treatment process. Overall spatial and dosimetric accuracy of the delivery were 1 mm and 3 % respectively.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

Extended cycle life implications of fast charging for lithium-ion battery cathode

Enabling extreme fast charging (XFC, =10–15 min charging) requires a comprehensive understanding of its implications. While lithium plating is a key bottleneck for the anode, the full extent of limitations for the cathode are not well-understood, particularly in extended-cycle settings with well-defined battery designs and conditions. This article presents cycle-life implications of XFC on cathodes at multiple length scales, combining electrochemical analyses, degradation modeling, and post-test characterizations. The comprehensive test matrix includes 41 well-defined gr/NMC pouch cells under varied fast-charge rates (1–9C) and state-of-charges cycled up to 1000 times. Cathode issues remain minimal in early cycling, but begin to accelerate in later life, when distinct cracking is found and identified as a fatigue mechanism. The bulk structure of cathodes remains intact, but distinct particle surface reconstruction is observed; however, this shows less pronounced effect on cathode aging than does cracking.

25 ENERGY STORAGE↗

DOE OSTI2018

Accelerated Stress Testing on Multichannel Drivers—Updated Test Results

This report is the second in a series of studies about accelerated stress testing (AST) of drivers used for SSL luminaires. Two-stage drivers intended for use in downlights, troffers and street lights were selected to undergo exposure to an AST environment consisting of 75°C and 75% relative humidity (7575). The 7575 AST environment was chosen for this study because a previous study demonstrated that 38% of a sample population of 6-inch downlights failed in less than 2,500 hours in these conditions. A mixture of single-channel (i.e., one output current channel designed for use with one LED primary) and multichannel (i.e., separate output current channels designed for use with multiple for LED primaries) two-stage drivers were exposed to the 7575 environment. This report provides updated AST test results for only the multichannel driver products. The multichannel driver population consisted of three products (with two-stage architecture) and a total of five samples. In addition to AST results, the product life distribution (Weibull analysis) of two-stage driver Hammer Test samples is reported.

42 ENGINEERING↗

DOE OSTI2010

Compression set in gas-blown condensation-cured polysiloxane elastomers

Accelerated thermal ageing studies on foamed condensation cured polysiloxane materials have been performed in support of life assessment and material replacement programmes. Two different types of filled hydrogen-blown and condensation cured polysiloxane foams were tested; commercial (RTV S5370), and an in-house formulated polysiloxane elastomer (Silfoam). Compression set properties were investigated using Thermomechanical (TMA) studies and compared against two separate longer term ageing trials carried out in air and in dry inert gas atmospheres using compression jigs. Isotherms measured from these studies were assessed using time-temperature (T/t) superposition. Acceleration factors were determined and fitted to Arrhenius kinetics. For both materials, the thermo-mechanical results were found to closely follow the longer term accelerated ageing trials. Comparison of the accelerated ageing data in dry nitrogen atmospheres against field trial results showed the accelerated ageing trends over predict, however the comparison is difficult as the field data suffer from significant component to component variability. Of the long term ageing trials reported here, those carried out in air deviate more significantly from field trials data compared to those carried out in dry nitrogen atmospheres. For field return samples, there is evidence for residual post-curing reactions influencing mechanical performance, which would accelerate compression set. Multiple quantum-NMR studies suggest that compression set is not associated with significant changes in net crosslink density, but that some degree of network rearrangement has occurred due to viscoelastic relaxation as well as bond breaking and forming processes, with possible post-curing reactions at early times.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2016

Polybenzimidazole (PBI) functionalized nanographene as highly stable catalyst support for polymer Electrolyte membrane fuel cells (PEMFCs)

Nanoscale graphenes were used as cathode catalyst supports in proton exchange membrane fuel cells (PEMFCs). Surface-initiated polymerization that covalently bonds polybenzimidazole (PBI) polymer on the surface of graphene supports enables the uniform distribution of the Pt nanoparticles, as well as allows the sealing of the unterminated carbon bonds usually present on the edge of graphene from the chemical reduction of graphene oxide. The nanographene effectively shortens the length of channels and pores for O 2 diffusion/water dissipation and significantly increases the primary pore volume. Further addition of p-phenyl sulfonic functional graphitic carbon particles as spacers, increases the specific volume of the secondary pores and greatly improves O 2 mass transport within the catalyst layers. The developed composite cathode catalyst of Pt/PBI-nanographene (50 wt%) + SO 3 H-graphitic carbon black demonstrates a higher beginning of life (BOL) PEMFC performance as compared to both Pt/PBI-nanographene (50 wt%) and Pt/PBI-graphene (50 wt%) + SO 3 H-graphitic carbon black (GCB). Accelerated stress tests show excellent support durability compared to that of traditional Pt/Vulcan XC72 catalysts, when subjected to 10,000 cycles from 1.0 V to 1.5 V. As a result, this study suggests the promise of using PBI-nanographene + SO 3 H-GCB hybrid supports in fuel cells to achieve the 2020 DOE targets for transportation applications.

30 DIRECT ENERGY CONVERSION↗

NASA NTRS1976

Accelerated test program for sealed nickel-cadmium spacecraft batteries/cells

The feasibility was examined of inducing an accelerated test on sealed Nickel-Cadmium batteries or cells as a tool for spacecraft projects and battery users to determine: (1) the prediction of life capability; (2) a method of evaluating the effect of design and component changes in cells; and (3) a means of reducing time and cost of cell testing.

Goodman, L. A.↗

DOE OSTI2016

Validation of a cyclic plasticity computational method using fatigue full-field deformation measurements

The evolution of crack tip displacement and strain fields during uniaxial, room temperature, low-cycle fatigue experiments of Nickel superalloy compact tension specimens was measured by a digital image correlation approach and was further used to validate a cyclic plasticity model and corresponding deformation calculations made by a finite elements methodology. The experimental results provided data trends for the opening displacements and near crack tip strains as function of cycles. A finite element model was developed to capture test conditions for a measured crack size. The model captures crack tip plasticity by using a constitutive model calibrated against stress-strain measurements performed on a round bar. Similar quantities were extracted from the model predictions to compare with the digital image correlation measurements for model validation purposes. This type of direct comparison demonstrated that the computational model was capable to adequately capture the crack opening displacements at various stages of the specimen's fatigue life, providing in this way a tool for quantitative cyclic plasticity model validation. In addition, this integrated experimental-computational approach provides a framework to accelerate our understanding related to interactions of fatigue test data and models, as well as ways to inform one another.

36 MATERIALS SCIENCE↗